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I'm in the process of building a loose clone of a sanitized Rhodie G1 in the style of the rifle featured in the recent Larry Vickers/Forgotten Weapons video. I have a 2012 DSA type 1 upper, a Belgian made RA marked type 1 lower, SA made NBC handguard, grenade gas plug, a chopped carry handle stub, and R marked selector with baby poop and beak ground off. The rest of the parts are a mix of Imbel and US copies of Imbel parts (922r). The only part that I'm knowingly leaving 'less-than-legit' is the stock, simply because I find the long stocks uncomfortable.

I'd like to find out if anyone has reproduced the sanitization marks, especially the large hole cut in the mag well to remove the SA crest. I've seen the hole listed as 1-1.2", and I'll probably have to eyeball the location based off the pics/video. The problem is - I've never drilled hole that large in hard metal before.

Any advice on drilling that hole or my build in general would be appreciated.

A carbide tooth hole saw would work for you with your drill press, I think. Dremel also makes a hole cutting attachment that's like $10 that you may want to look into. A machine shop would make short work of this for you. The problem would be finding one that would do it. Oh, if you decide to try it yourself practice on a piece of steel before you go after your receiver. :-)

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"The truth is incontrovertible; malice may attack it, ignorance may deride it, but in the end, there it is. "
-Winston Churchill-

A carbide tooth hole saw would work for you with your drill press, I think. Dremel also makes a hole cutting attachment that's like $10 that you may want to look into. A machine shop would make short work of this for you. The problem would be finding one that would do it. Oh, if you decide to try it yourself practice on a piece of steel before you go after your receiver. :-)

Definitely. I have some scrap steel laying around, but I'm sure it's not as hard as the receiver, although it's at least twice as thick.

I'm also planning on cutting a piece of it to clamp to the inside of the magwell as a backing. I've read that this will leave a cleaner hole.

Still need to figure out the exact size I want to go with and what I'm going to do about the bare metal exposed. Also wondering if they chamfered the hole at all...

Hole saws make a shit-looking hole. Go the annular cutter route if you don’t want hole edges to look like they were cut by Century Arms.

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Future Crotchety Ol' Bastard

“I’m saying: Think about your contribution to society. Be careful when you get into a business that extracts value. Broaden your idea about what’s enough. And for God’s sake, think about who you are.” - J. Bogle

If you really want pretty and perfect though wire EDM is your friend. Then again we're talking about the Rhodies. Didn't they care about pretty about as much as they cared about their serializing and paint jobs?

Shelby Cobra. Possibly the greatest car of all time. If you find one with perfect sheetmetal it is imperfect. The fenders and other panels were hand hammered over dies. When the hammering makes are removed it actually detracts from the original state of the Cobra sheetmetal. In other words, imperfect IS perfect.

While I'm not versed in the Rhodie sterilizations, I can't see them putting the artisanal craftsmen taken from Holland and Holland in the dead of the night to ensure the perfection of the hole.